Influence of Welding Tool Material and Type of Joint on the Formability of Friction Stir Welded Tailored Blanks

Emerging process limits in sheet metal forming of tailored blanks are determined by the mechanical properties of semi-finished sheet materials to be joined and the type of weld seam. The weld seam properties in turn depend on the welding tool material and the utilized process parameters. In this study, tailored blanks were produced made of aluminum AA6016 (2 mm) and the steel grade DX54 (1 mm) as well as from AA6016 (2 mm) and HX380 (1 mm) using different welding tool materials such as steel and ceramics. The joint between both blanks was performed as a butt joint or combined lap-/butt-joint. The formability of the tailored blanks produced in this way was investigated using a three-point bending device. The tests carried out were evaluated with regard to the maximum bending force. Best results were obtained for tailored blanks produced with ceramic welding tools producing a combined lap-/butt-joint.